Slot core transformers

Abstract

Slot core inductors and transformers and methods for manufacturing same including using large scale flex circuitry manufacturing methods and machinery for providing two mating halves of a transformer winding. One winding is inserted into the slot of a slot core and one winding is located proximate to the exterior wall of the slot core. These respective halves are joined together using solder pads or the like to form continues windings through the slot and around the slotted core.

What is claimed is:  
     
       1. The method of manufacturing slotted E-core inductors and transformers comprising: 
       forming a first plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;  
       forming a second plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;  
       covering said etched copper electrical conductors while leaving access holes that expose said copper conductors to provide solder pads;  
       separating a chain of said first plurality of spaced discrete electrical conductors;  
       separating a chain of said second plurality of spaced discrete electrical conductors;  
       folding said first plurality of spaced discrete electrical conductors to form at least three cavities;  
       inserting the three legs of a two-piece E-core into respective ones of said cavities so that a portion of said conductors extend into the slot of said core;  
       covering the ends of said three legs with the cover piece of said two-piece E-core;  
       locating a second plurality of spaced discrete electrical conductors over the three legs of said E-core; and  
       bonding together respective solder paths of both the first and second chains of electrical conductors.  
     
     
       2. The method of manufacturing slotted core inductors and transformers comprising: 
       forming a first plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;  
       forming a second plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;  
       covering said etched copper electrical conductors while leaving access holes that expose said copper conductors to provide solder pads;  
       separating a chain of said first plurality of spaced discrete electrical conductors;  
       separating a chain of said second plurality of spaced discrete electrical conductors;  
       folding said first plurality of spaced discrete electrical conductors to form a cavity;  
       inserting one or more slot cores into said cavity so that a portion of said conductors extend into the slot of said core;  
       locating a second plurality of spaced discrete electrical conductors over said core or cores; and  
       bonding together respective solder paths or both the first and second chains of electrical conductors.  
     
     
       3. The method of manufacturing slotted core inductors and transformers comprising: 
       forming a first plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;  
       forming a second plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;  
       covering said etched copper electrical conductors while leaving access holes that expose said copper conductors to provide solder pads;  
       separating a chain of said first plurality of spaced discrete electrical conductors;  
       separating a chain of said second plurality of spaced discrete electrical conductors;  
       inserting said first chains into slots of one or more slot cores so that a portion of said conductors extend into the slot of said core;  
       locating a second plurality of spaced discrete electrical conductors over said core or cores; and  
       bonding together respective solder pads of both the first and second chains of electrical conductors.